Vehicle Bumper Beam with Open Hat Profile and Indentation

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Solution Overview

Problem

Existing bumper designs often compromise between strength and weight, and fail to optimize space for vehicle design, as they either prioritize one over the other or lack effective energy absorption in collisions.

Innovation Solution

A bumper beam with a hat profile and side flanges, featuring a cover that leaves the outer portions open, a longitudinal indentation, and mountings that provide structural support and energy absorption through an integrated EPP foam body, allowing for a sturdy yet lightweight design that maintains strength even at the ends.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the bumper beam uses a closed profile design, then strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidbumper beam weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The bumper beam applies local quality by providing a closed profile at the critical mounting areas for maximum strength, while leaving the outer portions open to reduce weight. The crown height varies along the length, being higher at mounting locations and lower at outer portions, optimizing strength-to-weight ratio locally at different positions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The bumper beam is segmented into different functional zones: closed profile sections at mountings for strength, and open profile sections at outer portions for weight reduction. This segmentation allows each part to serve its specific function optimally without compromising overall performance.

Inventive Principle:

Principle #1Segmentation

2Weight of moving object

If the bumper beam uses a reduced profile at outer portions, then weight is reduced, but strength decreases

Engineering Contradiction:

Improvebumper beam weightVSAvoidstrength at ends

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The longitudinal indentation in the crown creates local reinforcement zones at strategic positions, particularly at the outer portions where the profile is reduced. This allows the beam to maintain adequate strength at critical locations while keeping the overall weight reduced through the variable profile design.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If the cover extends past the mountings, then design space is optimized, but manufacturing complexity increases

Engineering Contradiction:

Improvedesign spaceVSAvoidmanufacturing complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The cover is segmented to extend only to specific positions relative to the mountings, providing adequate design space while avoiding unnecessary extension that would increase manufacturing complexity. This segmented approach allows the cover to serve its protective and aesthetic functions without adding undue complexity.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS7938462B2Bumper beam

Publication Date: 2011.05.10 GESTAMP HARDTECH AB

AI summary

A bumper beam for a vehicle has a hat shaped profile with the crown (12-14) facing the vehicle and has a cover (17) that gives the bumper beam a closed profile. The bumper beam has two mountings (20, 21) that usually are adapted to be fitted to the side rails of the vehicle. The cover is extended on both sides past the mountings, but leaves the outer portions of the hat beam open. The crown of the open portions of the hat beam have a longitudinal indentation (32) and a profile height that decreases towards the ends.